Safety module electrical distribution system

ABSTRACT

A wiring module that can be installed in an electrical junction box and can receive a removable electrical outlet module, a removable electrical switch module, or other types of electrical functional modules. The wiring module and the removable electrical outlet and switch modules may include connectors having a mechanical portion and an electrical portion. The electrical connector portions may be configured so as not to be exposed to user contact when the mechanical connector portions are at least partially engaged.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/780,687, filed May 14, 2010, entitled SAFETY MODULE ELECTRICALDISTRIBUTION SYSTEM, which is a continuation of U.S. patent applicationSer. No. 12/106,984, entitled SAFETY MODULE ELECTRICAL DISTRIBUTIONSYSTEM, filed Apr. 21, 2008, now U.S. Pat. No. 7,762,838, which is acontinuation of U.S. patent application Ser. No. 11/493,366, entitledSAFETY MODULE ELECTRICAL DISTRIBUTION SYSTEM, filed Jul. 25, 2006, nowU.S. Pat. No. 7,361,051, which is a continuation of U.S. patentapplication Ser. No. 11/110,659 entitled SAFETY MODULE ELECTRICALDISTRIBUTION SYSTEM, filed Apr. 20, 2005, now U.S. Pat. No. 7,081,010which is a continuation of U.S. patent application Ser. No. 10/443,444entitled SAFETY MODULE ELECTRICAL DISTRIBUTION SYSTEM, filed May 22,2003, now U.S. Pat. No. 6,884,111, which relates to and claims thebenefit of prior U.S. Provisional Applications No. 60/383,269, filed May23, 2002, entitled SAFETY PLUG-IN MODULE ELECTRICAL DISTRIBUTION SYSTEM,and No. 60/441,852, filed Jan. 21, 2003, entitled SAFETY MODULEELECTRICAL DISTRIBUTION SYSTEM. All of the aforementioned priorapplications are hereby incorporated by reference in their entiretyherein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Standard AC electrical systems are comprised of an electrical box and anelectrical device, such as an outlet or switch, installed within thebox. During a roughing phase of construction, electrical boxes aremounted to wall studs at predetermined locations. After the boxes areinstalled, a journeyman electrician routes power cables through buildingframing to the appropriate boxes. The power cable is fed throughopenings in the rear or sides of the electrical boxes and folded backinto the boxes, unterminated, so as to be out of the way until the nextphase. During a makeup phase, wall panels are installed and painted, andthe journeyman returns to the construction site to install theelectrical devices into the boxes. After conductors are wired to anelectrical device, it and the attached conductors are pushed into theelectrical box and the device is attached to the top and bottom of thebox with screws. During a trim phase, face plates are mounted over theopen-end of the electrical boxes, completing the standard electricalwiring process.

2. Description of the Related Art

Standard AC electrical systems are problematic in construction and use,with respect to costs, safety and functionality. From an electricalcontractor perspective, a journeyman electrician must make two separatetrips to the job site, one for the rough phase and one for the makeupphase. Also, during the makeup phase, installation of the wall panelscan damage the work completed during the rough phase. This occurs, forexample, when a router contacts exposed cables as drywallers create ahole to accommodate electrical box openings. Another form of damageoccurs when drywall compound or paint fouls the exposed cables,insulation and labeling.

From a general contractor's perspective, verification of the electricalcontractor's work is not possible until after the makeup phase. Untilthen, the electrical cables are unterminated. After the makeup phase,however, miswiring typically requires cutouts in the installed wallpanels and associated patches after corrections are completed. Further,the electrical system cannot be activated until after verification.Thus, during the rough and makeup phases, electricity for tools andlighting must be supplied by generators, which create hazards due tofumes, fuel, and noise and are an unreliable electrical source. Inaddition, until the trim phase is completed, unskilled personnel haveaccess to the electrical cable. Tampering can compromise the integrityof the electrical wiring and also create a safety problem after power isactivated.

From a homeowner's perspective, there are problems with repair of thestandard electrical wiring. Replacement of a broken outlet or switchdevice first requires removal of a face plate. The screws that attachthe module to the top and bottom of the electrical box must be removednext. The device is then removed from the box and the conductors areremoved by loosing the screws on the outlet sides. The process is thenreversed to attach the conductors to a new device and mount the newdevice into the electrical box.

The prior art electrical device replacement procedure described aboveexposes the homeowner to AC wiring upon removal of the face plate. Thisexposure creates a shock hazard. Further, a homeowner's reluctance tochange out broken devices or to spend the money to hire an electricianalso creates a shock and a fire hazard from continued use of cracked,broken or excessively worn outlets or switches. In addition, theintegrity of the original wiring becomes questionable if a homeowner orother third party removes and replaces an electrical device. Miswiringby a third party can violate building codes and create shock and firehazards, such as inadvertently switching the hot and neutral conductors,failing to attach ground wires, kinking or nicking conductors orimproperly tightening connections.

A safety module electrical distribution system benefits the electricalcontractor in several respects. A wiring module is installed internallyto an electrical box and associated functional modules are removablyinstalled into the wiring module without exposure to or access toelectrical system wiring attached behind the panel. The journeyman'swork can be completed at the rough phase, when installation of thewiring module is complete. Thus, there is no need for the journeyman toreturn to the job site during the makeup phase because any semi-skilledlaborer can insert, for example, an appropriate outlet or switch module.Further, there is no wiring access after the rough phase, protectingwiring integrity. Also, there are no exposed conductors or parts insidethe electrical box that can be inadvertently damaged during wall panelinstallation.

The safety module electrical distribution system also benefits thegeneral contractor. Because wiring is completed during rough framing,verification and activation of the building electrical system can beperformed at the rough phase. Miswiring can be corrected before wallpanels are installed and painted, eliminating cut and patch repairs.Early electrical system activation eliminates the need to usegenerators. Lack of third party access to the journeyman's wiringpreserves integrity after verification and eliminates shock exposure toother workers.

The safety module electrical distribution system also benefits thehomeowner. Replacement of broken sockets and switches can be easily andsafely accomplished. Safety is enhanced by reducing exposure toelectrical wiring and encouraging replacement of defective outlets andswitches. Further, maintenance costs are reduced by reducing the need tohire an electrician for repairs. Wiring integrity is insured by reducingthe opportunity of unqualified third parties to access the electricalsystem.

SUMMARY OF THE INVENTION

Various embodiments of a safety module electrical distribution systemare described herein. In some embodiments, a safety module electricaldistribution system comprises a wiring module adapted to mount within anelectrical box, the wiring module having a functional side and a wiringside. A terminal set is disposed at least partially within the wiringmodule and is adapted to terminate a power cable proximate the wiringside. A plurality of structured sockets are disposed on the functionalside, the structured sockets incorporate a portion of the terminal set.A functional module having a front side and a back side is adapted toremovably install in the wiring module proximate the functional side. Acontact set is disposed at least partially within the functional moduleand is adapted to conduct electrical power to an electrical distributionfunction accessible from the front side. A plurality of shielded plugsare disposed on the back side. The shielded plugs incorporate a portionof the contact set. The structured sockets are configured to interlockwith the shielded plugs so as to provide electrical communicationbetween the terminal set and said contact set.

In one embodiment the structured sockets comprise raised guards andsurrounding channels. The shielded plugs comprise contiguous wallsdisposed around the peripheries of, and extending about the length of,prong portions of the contact set, where the walls define open endsdistal the back side. The walls mate with the channels and the raisedguards insert into the open ends. A key extends from, and is positionedon, the back side so as to identify a type of the functional module. Ablock is positioned on the functional side so as to accept the key onlywhen the functional module is properly oriented with respect to thewiring module. The wiring module is oriented within the electrical boxaccording to the type. The key is an off-center positioned bar and theblock is an off-center positioned ground socket. The bar is configuredto insert into the ground socket.

In another embodiment, a plurality of color-coded wiring labels aredisposed on the functional side, and a color-coded module label isdisposed on the functional module. A marked one of the wiring labelsindicate a particular wiring configuration of the wiring panel, and thecolor of the marked one corresponds to the color of the module labelonly if the functional module corresponds to the particular wiringconfiguration. In a further embodiment, the terminal set comprises aplurality of terminal blocks, where each of the terminal blocks areadapted to terminate up to four wires. In yet another embodiment, theterminal set comprises a plurality of fixed wires extending from thewiring side, where each of the fixed wires have a push-wire connectorinstalled distal the wiring side. In an additional embodiment, anelectrical box cover is adapted to clamp onto a mounting bracket portionof the wiring module so as to mount flush with the open face of theelectrical box.

Another aspect of a safety module electrical distribution systemcomprises a wiring module adapted to mount within an electrical box. Thewiring module has a functional side adapted to removably connect with afunctional module and an opposite wiring side. A conductive terminal setis at least partially disposed proximate the wiring side and adapted toterminate a power cable. A structured socket disposed on the functionalside has a nonconductive portion and a terminal set portion. Thenonconductive portion is configured to insert within a correspondingnonconductive portion of the functional module so as to provide a fullyenclosed shield as the terminal set portion receives a correspondingconductive portion of the functional module.

In one embodiment, the functional module comprises a front coverdefining the front side and a back cover defining the back side. Thefront cover has a latch, and the back cover has a corresponding catch.The covers are configured to attach together, with the latch securing tothe catch, so as to enclose at least a portion of the contact set. Thefunctional module may have a key identifying a functional module typeand insuring proper orientation of the functional module with respect tothe wiring module according to its type. In a particular embodiment, thefunctional module is a switch type and the key is a nonconductive barpositioned off-center on, and extending from, the back cover.

In one embodiment, the wiring module further comprises a front coverdefining the functional side, a back cover defining the wiring side, anda bracket configured to mount the wiring module to the box. The coversattach together so as to enclose at least a portion of the terminal setand to secure the bracket between the covers. The terminal set maycomprise a plurality of terminal blocks each adapted to terminate eitherfour 14 gauge wires or two 12 gauge wires.

In another embodiment, the wiring module further comprises a front coverdefining the functional side, a back cover defining the wiring side, anda bracket disposed around the back cover and secured to the front coverso as to hold together the front and back covers. The bracket isconfigured to mount the wiring module to the box and to ground thefunctional module. In a particular embodiment, the back cover defines aplurality of wire apertures and the terminal set comprises a pluralityof fixed wire terminals and a corresponding plurality of fixed wires.Each of the fixed wires has a striped wire end and a connector end andextend through a corresponding one of the wire apertures. The stripedwire ends connect to the fixed wire terminals. The connector end isadapted to terminate at least a portion of the power cable.

A further aspect of a safety module electrical distribution system is afunctional module adapted to removably connect to a wiring modulemounted within an electrical box and connected to a power cable. Thefunctional module has a front side providing access to an electricalfunction, an opposite back side, and a contact set. A shielded plugdisposed on the back side has an insulating shield disposed around aplug portion of the contact set. The insulating shield is configured toboth plug into and accept corresponding nonconductive portions of thewiring module so as to fully enclose the plug portion when in electricalcommunication with the power cable.

In some embodiments, an electrical distribution apparatus comprises: ahousing having a front cover with a front face that defines anelectrical distribution function, and a back cover with a back facehaving a plurality of shielded plugs; an electrical contact set at leastpartially enclosed by the housing, wherein said electrical contact setis adapted to communicate electrical power via said shielded plugs forsaid electrical distribution function, and wherein each of the shieldedplugs comprises a prong and a wall protruding from the back face, thewall disposed around the prong and protruding further than the prong.

In some embodiments, an electrical distribution apparatus comprises: anon-electrically conductive body comprising a front side and a backside; a first set of one or more connectors proximate the front sideconfigured to couple with a removable electrical outlet module or aremovable electrical switch module, the first set of one or moreconnectors each comprising a mechanical connector portion and anelectrical connector portion, the electrical connector portionconfigured so as not to be exposed to user contact when the mechanicalconnector portion is at least partially engaged with a complementarymechanical connector portion of the removable electrical outlet moduleor the removable electrical switch module; a second set of one or moreconnectors proximate the back side configured to electrically couplewith one or more electrical power cables; and one or more electricalconductors within the body configured to electrically couple the firstset of one or more connectors with the second set of one or moreconnectors.

In some embodiments, an electrical distribution apparatus comprises: anon-electrically conductive body comprising a user-accessible front sideand a back side; a first set of one or more connectors proximate theback side configured to couple with a wiring module connected to asource of electrical power, the first set of one or more connectors eachcomprising a mechanical connector portion and an electrical connectorportion, the electrical connector portion configured so as not to beexposed to user contact when the mechanical connector portion is atleast partially engaged with a complementary mechanical connectorportion of the wiring module.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-B are perspective views of an outlet module installed andremoved, respectively, from a corresponding wiring module;

FIGS. 2A-B are perspective views of a switch module installed andremoved, respectively, from a corresponding wiring module;

FIGS. 3-8 are perspective views of an outlet module and outlet modulecomponents;

FIGS. 3A-B are front and back perspective views, respectively, of anoutlet module;

FIGS. 4A-B are exploded, front perspective views of outlet modules;

FIGS. 5A-B are front and back perspective views, respectively, of anoutlet module front cover;

FIGS. 6A-B are front and back perspective views, respectively, of anoutlet module back cover;

FIGS. 7A-B are front and back perspective views, respectively, of anoutlet module power contact set;

FIGS. 8A-B are front and back perspective views, respectively, of anoutlet module ground contact set;

FIGS. 9-15 are perspective views of a switch module and switch modulecomponents;

FIGS. 9A-B are front and back perspective views, respectively, of aswitch module;

FIG. 10 is an exploded, front perspective view of a switch module;

FIGS. 11A-B are front and back perspective views, respectively, of aswitch module switch;

FIGS. 12A-B are front and back perspective views, respectively, of aswitch module front cover;

FIGS. 13A-B are front and back perspective views, respectively, of aswitch module single-pole, single throw (SPST) contact set;

FIGS. 13C-D are front and back perspective views, respectively, of aswitch module single-pole, double throw (SPDT) contact set;

FIGS. 13E-F are front and back perspective views, respectively, of aswitch module double-pole, double throw (DPDT) contact set;

FIGS. 14A-B are front and back perspective views, respectively, of aswitch module actuator;

FIGS. 15A-B are front and back perspective views, respectively, of aswitch module back cover;

FIGS. 16-22 are perspective views of a wiring module and wiring modulecomponents;

FIGS. 16A-B are front and back perspective views, respectively, of aterminal-block wiring module;

FIGS. 16C-D are back perspective views of a terminal-block wiring moduleand associated terminal guards in open positions;

FIGS. 16E-F are front and back views, respectively, of a terminal-blockwiring module and position-dependent wiring labels;

FIGS. 16G-H are switch and outlet wiring schematics, respectively;

FIG. 17A-B are exploded, front perspective views of a terminal-blockwiring module with stationary-mount and swivel-mount terminal guards,respectively;

FIGS. 18A-B are front and back perspective views and a back view,respectively, of a wiring panel;

FIGS. 19A-B are front and back perspective views, respectively, of amounting bracket;

FIGS. 20A-B are front and back perspective views, respectively, of awiring panel front cover;

FIG. 21 is a perspective view of a wiring panel terminal set;

FIGS. 22A-B are front and back perspective views, respectively, of awiring panel back cover;

FIGS. 23A-B are front and back perspective views, respectively, of adimmer switch module;

FIG. 24 is an exploded, front perspective view of a dimmer switchmodule;

FIGS. 25A-B are front and back perspective views, respectively, of afixed-wire wiring module;

FIGS. 26A-B are exploded, front and back perspective views,respectively, of a fixed-wire wiring module;

FIGS. 27A-B are front and back perspective views, respectively, of anelectrical box cover;

FIGS. 28A-B are front perspective views of a covered and uncoveredelectrical box, respectively;

FIG. 29 is a front perspective view of a 2-gang electrical box withoverlapping covers;

FIGS. 30A-B are back perspective and back perspective exploded views,respectively, of a wiring module having a terminal shield; and

FIGS. 31A-B are front and back perspective views, respectively, of aterminal shield.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT System Overview

FIGS. 1-2 illustrate a safety module electrical distribution system 100having a functional module 110 and a wiring module 1600. The electricaldistribution system 100 is configured to mount within a standardelectrical box (not shown), such as is typically installed within abuilding wall. In particular, the wiring module 1600 is configured to beeasily installed within an electrical box, and a functional module 110is configured to be removably plugged into the wiring module 1600, asdescribed below. FIGS. 1A B show an outlet module 300 in an installedand a removed position, respectively. FIGS. 2A-B show a switch module900 in an installed and a removed position, respectively. A face plate(not shown) may be installed over a functional module 110 so as toprovide an aesthetic trim.

As shown in FIGS. 1-2, each functional module 110 provides auser-accessible electrical distribution function. As shown in FIGS.1A-B, the functional module 110 may be an outlet module 300, whichfunctions to supply a user with electrical power through a conventionalAC plug inserted into one of the module sockets. The outlet module 300is configured for installation in a ground-up position in a wiringmodule 1600 oriented for outlet installation. Alternatively, an outletmodule and wiring module can be configured for outlet installation in aground-down position.

As shown in FIGS. 2A-B, the functional module 110 may be a switch module900, which allows a user to control electrical power to an outlet, alight or any of various electrical devices (not shown) by actuating themodule switch. The switch is slidable between first and second positionsin contrast to a conventional toggle switch, such as used for turning aninterior light on and off. The switch module 900 is configured forinstallation in a wiring module 1600 oriented for switch installation.Reversible wiring module 1600 orientation within an electrical box toindicate the module to be installed and its proper orientation isdescribed in detail with respect to FIGS. 16A-H, below

Other outlet and switch related functional modules 110 may include GFCIoutlets, covered safety outlets and dimmer switches (FIGS. 23-24) toname just a few. Further, the electrical distribution system 100 may bewall-mounted, ceiling-mounted or floor-mounted. In additional, theelectrical distribution system 100 can be adapted for uses other thanbuilding electrical distribution, such as airplane, automobile or boatelectrical distribution applications, to name a few. A modularelectrical outlet and switch system is described in U.S. Pat. No.6,341,981 entitled Safety Electrical Outlet and Switch System, and acovered safety outlet module is described in U.S. patent applicationSer. No. 10/737,713 entitled Safety Outlet Module, both assigned toProtectConnect, Irvine, Calif. and incorporated by reference herein.

Outlet Module

FIGS. 3A-B illustrate an outlet module 300 having a body 310, a frontside 301 and a back side 302. The body 310 accepts attachment screws 305on diagonally opposite corners that are utilized to secure the outletmodule 300 to a wiring module 1600 (FIGS. 1A-B). The outlet module frontside 301 provides upper and lower sockets 320 each configured to accepta conventional, three-wire (grounded) electrical plug. The outlet moduleback side 302 provides shielded plugs 330 and a ground bar 834 thatphysically and electrically connect the outlet module 300 to a wiringmodule 1600 (FIGS. 1A-B). The shielded plugs 330 transfer electricalpower to the sockets 320, and the ground bar 834 provides a ground pathfor the sockets 320. The ground bar 834 also functions as a key toassist in orienting the outlet module 300 relative to the wiring module1600 (FIGS. 1A-B).

FIG. 4A illustrates an outlet module 300 having a front cover 500, arear cover 600, a power contact set 700 and a ground contact set 800.The front cover 500 and back cover 600 form the outlet module body 310(FIGS. 3A-B). The covers 500, 600 advantageously snap together with alatch and catch assembly, described with respect to FIGS. 5-6, below.This reduces manufacturing assembly steps and reduces or eliminates theneed for separate fasteners, such as rivets or screws and/or sonicwelding. The contact set 700, 800 is retained within the covers 500, 600and provides conductive paths from the wiring panel 1600 (FIGS. 16A-B)to the outlet sockets 320 (FIG. 3A). In particular, a power contact set700 transfers power from the shielded plugs 330 (FIG. 3B) to the outletsockets 320 (FIG. 3A). A ground contact set 800 provides a ground pathbetween a ground bar 834 (FIG. 3B) and the outlet sockets 320 (FIG. 3A).The ground contact set components 810, 830, 850 are assembled asdescribed with respect to FIGS. 8A-B, below. In one embodiment, thecovers 500, 600 are constructed of nylon. FIG. 4B illustrates analternative embodiment of an outlet module 400, such as for 20Aapplications

FIGS. 5A-B illustrate the outlet module front cover 500 having anoutside face 501, an inside face 502, outlet apertures 510, attachmentears 520, side latches 530 and contact housing structure 540, 550. Asshown in FIG. 5A on the outside face 501, the outlet apertures 510 formthe entry to the outlet module sockets 320 (FIG. 3A) and include a hotslot, neutral slot and ground hole for each of a top socket and bottomsocket. The attachment ears 520 are advantageously integral to the frontcover 500, eliminating the need for a separate mechanism for attachingthe outlet module 300 (FIGS. 3A-B) to the wiring module 1600 (FIGS.16A-B). The attachment ears 520 are located at an upper right corner anda diagonally opposite lower left corner (not visible), and each has afastening aperture that accepts, for example, an attachment screw 305(FIGS. 3A-B). The side latches 530 form the front cover portion of thelatch and catch assembly, functionally described with respect to FIG. 4,above.

As shown in FIG. 5B on the inside face 502, a power contact structure540 accepts the power contact set 700 (FIGS. 7A-B) so that the powercontact clips 701 (FIGS. 7A-B) align with the hot and neutral slots ofthe outlet apertures 510. A ground contact structure 550 accepts theground contact set 800 (FIGS. 8A-B) so that the ground contact clips832, 852 (FIGS. 8A-B) align with the ground holes of the outletapertures 510.

FIGS. 6A-B illustrate the outlet module back cover 600 having an outsideface 601, an inside face 602, plug shields 610, a ground bar aperture620, side catches 630 and contact support structure 640, 650. As shownin FIG. 6B on the outside face 601, the plug shields 610 advantageouslyprovide the shield portion of the shielded plugs 330 (FIG. 3B).Specifically, the plug shields 610 completely surround all sides of thepower contact set prongs 702 (FIGS. 7A-B). In this manner, the prongs702 (FIGS. 7A-B) are not exposed when the outlet module plugs 330 (FIG.3B) are engaged with the wiring module sockets 810 (FIG. 18A), even whenthe outlet module 300 (FIGS. 3A-B) is partially separated from thewiring module 1600 (FIGS. 16A-B). The ground bar aperture 620 allows theground bar 834 (FIGS. 8A-B) to protrude through the back cover 600,providing a ground contact with the wiring module 1600 (FIGS. 16A-B).The side catches 630 provide apertures that accept and engage the sidelatches 530 (FIGS. 5A-B) so as to releasably secure together the frontcover 500 (FIGS. 5A-B) and the back cover 600.

As shown in FIG. 6A on the inside face 602, a power contact supportstructure 640 consists of slots that allow the prongs 702 (FIGS. 7A-B)to protrude through the back cover 600 within the plug shields 610,providing a power connection with the wiring module 1600 (FIGS. 16A-B).A ground contact support structure 650 supports the ground contact set800 (FIGS. 8A-B).

FIGS. 7A-B illustrate the power contact set 700 having an upper hotcontact 710, a lower hot contact 720, an upper neutral contact 730 and alower neutral contact 740. Each contact 710 740 has a prong clip 701interconnected with a prong 702. The prong clips 701 align with thefront cover hot and neutral slots 510 (FIG. 5A) to form the outletmodule sockets 320 (FIG. 3A). The prongs 702 insert through the powercontact support structure 640 into the plug shields 610 to form theoutlet module shielded plugs 330 (FIG. 3B). Advantageously, the powercontact set 700 is configured so that the contacts may be manufacturedby a stamp and fold process. In one embodiment, the contacts are brass.

FIGS. 8A-B illustrate a ground contact set 800 having a ground buss 810,an upper ground contact 830 and a lower ground contact 850. The groundclips 832, 852 align with the front cover ground holes 510 (FIG. 5A) toform the ground portion of the outlet module sockets 320 (FIG. 3A). Theground bar 834 protrudes through the back cover 600 (FIGS. 6A-B) toprovide a ground path connection with the wiring module 1600 (FIGS.16A-B). The unassembled ground contact set 800 is illustrated in FIG. 4,above. Ground contact set 800 assembly is described below.

As shown in FIGS. 8A-B, the ground buss 810 has an upper rivet 812, alower rivet 814, an upper cutout 815, a slot 816 and a lower cutout 818.The ground buss 810 mechanically supports and electrically interconnectsthe upper ground contact 830 and the lower ground contact 850. The upperground contact 830 has an upper ground clip 832, a ground bar 834,leaves 836 and a tab 838. The upper ground clip 832 and ground bar 834extend from opposite ends of the upper ground contact 830. The upperground clip 832 accepts a ground pin from a standard AC electrical plug.The ground bar 834 inserts into a corresponding ground clip 1902 (FIGS.19A-B) in the wiring module 1600 (FIGS. 16A-B). The tab 838 extendsgenerally perpendicularly below and between the clip 832 and bar 834 andhas an aperture corresponding to the top rivet 812. The leaves 836extend from the back of the clip 832. The lower ground contact 850 has alower ground clip 852, leaves 854 and a tab 858. The tab 858 extendsgenerally perpendicularly to the clip 852 and has an aperturecorresponding to the lower rivet 814. The leaves 854 extend from theback of the clip 852.

Also shown in FIGS. 8A-B, the ground contact set 800 is assembled byinserting the upper ground contact 830 and lower ground contact 850 intothe ground buss 810. Specifically, the ground bar 834 is inserted intothe slot 816, the leaves 836, 854 are inserted into the upper and lowercutouts 815, 818, respectively, and the upper and lower rivets 812, 814are inserted through the tabs 838, 858. The rivets 812, 814 are thensplayed, fixedly attaching the upper and lower ground contacts 830, 850to the ground buss 810. Advantageously, the ground contact set 800 isconfigured so that the ground contact set components 810, 830, 850 maybe manufactured by a stamp and fold process. In one embodiment, theupper and lower ground contacts 830, 850 are brass and the ground buss810 is zinc-plated steel.

Switch Module

FIGS. 9A-B illustrate a switch module 900 having a body 910, a frontside 901 and a back side 902. Like the outlet module body 310 (FIGS.3A-B), the switch module body 910 accepts screws on diagonally oppositecorners that are utilized to secure the switch module 900 to a wiringmodule 1600 (FIGS. 2A-B). The switch module front side 901 has aslidable switch 1100 configured to actuate internal contacts so as toroute electrical power, to turn on and off a light, for example. Likethe outlet module 300 (FIGS. 3A-B), the switch module back side 902provides shielded plugs 930 that physically and electrically connect theswitch module 900 to a wiring module 1600 (FIGS. 2A-B). The shieldedplugs 930 conduct electrical power under control of the switch 1100.There may be null plugs 940 having no conductors depending on the switchmodule 900 configuration and associated function, as described withrespect to FIGS. 13A-F, below. The switch module 900 does not require aground path to the wiring module 1600 (FIGS. 2A-B). A key bar 1520,therefore, provides a non-conducting structure that substitutes for aground bar 834 (FIG. 3B), to assist in orienting the switch module 900relative to the wiring module 1600 (FIGS. 2A-B).

FIG. 10 illustrates a switch module 900 having a switch 1100, a frontcover 1200, a rear cover 1500, a contact set 1300, an actuator 1400 anda spring 1000. The front cover 1200 and back cover 1500 form the switchmodule body 910 (FIGS. 9A-B). The covers 1200, 1500 advantageously snaptogether and are secured with a latch and catch assembly, described withrespect to FIGS. 12A-B and 15A-B, below. This reduces manufacturingassembly steps and reduces or eliminates the need for separatefasteners, such as rivets or screws and/or sonic welding. In oneembodiment, the covers 1200, 1500 are constructed of nylon.

As shown in FIG. 10, the switch 1100 snaps into and is slidably retainedby the front cover 1200 and engages the actuator 1400. The switch 1100is movable between a first position and a second position. The contactset 1300, actuator 1400 and spring 1000 are retained within the covers1200, 1500. The contact set 1300 routes electrical power from the wiringpanel 1600 (FIGS. 1A-B) as determined by the switch 1100 positions. Inparticular, the position of the switch 1100 determines the position ofthe actuator 1400, which, in turn, determines whether the contact set1300 is open or closed. If closed, the contact set 1300 provides aconductive path that transfers power between the shielded plugs 930(FIG. 3B). The switch 1100 remains in its manually set position undertension from the spring 1000.

FIGS. 11A-B illustrate a switch 1100 that is generally rectangular,having a front side 1101 and a back side 1102. The front side 1101 has afinger grip 1110 for manually sliding the switch between its firstposition and its second position, as described above. The back side 1102has latches 1120 and a lever 1130 that extends in a direction generallynormal to the plane of the back side 1102. The latches 1120 areconfigured to pass through front cover slots 1214 (FIG. 12A), whichcause the latches 1120 to flex inward toward the extension 1130 as theswitch 1100 is pressed into the front cover 1200 (FIGS. 12A-B). Thelatches 1120 spring outward after the latches pass through the slots1214 (FIG. 12A), seating the switch in the front cover 1200 (FIGS.12A-B), as described below. The lever tip 1132 inserts through theactuator slot 1410 (FIGS. 14A-B) and contacts the spring 1000,mechanically connecting the switch 1100 to the actuator 1400 (FIGS.14A-B).

FIGS. 12A-B illustrate a front cover 1200 having an outside face 1201,an inside face 1202, a switch cavity 1210, attachment ears 1220, sidelatches 1230 and top and bottom catches 1240. Located on the outsideface 1201, the cavity 1210 is configured to accommodate the switch 1100(FIGS. 11A-B). Within the cavity 1210 is a lever slot 1212 that allowsthe switch lever 1130 (FIG. 11B) to pass through the front cover to theactuator 1400 (FIGS. 14A-B). The lever slot 1212 extends along thecavity 1210 a sufficient distance to allow switch movement between firstand second positions, as described above. Also within the cavity 1210are catch slots 1214 that accommodate and capture the switch latches1120 (FIG. 11B), as described above. The attachment ears 1220 arelocated at an upper right corner and a diagonally opposite lower leftcorner (not visible), and each has a fastening aperture that accepts,for example, an attachment screw 305 (FIGS. 3A-B). The side latches 1230and top and bottom catches 1240 form the front cover portion of thelatch and catch assembly, functionally described with respect to FIG.10, above.

FIGS. 13A-B illustrate a SPST contact set 1300 having a throw buss 1310and a pole buss 1320. The throw buss 1310 has a first prong 1312, aflexible throw 1314 and a throw contact 1318. The pole buss 1320 has asecond prong 1322, a fixed pole 1324 and a pole contact 1328. The firstand second prongs 1312, 1322 form the conductive portion of the shieldedplugs 930 (FIG. 9B). The flexible throw 1314 engages the actuator 1400,as described with respect to FIGS. 14A-B, below, which moves the throwbetween an open position and a closed position (shown). In the closedposition, the throw contact 1318 touches and electrically connects withthe pole contact 1328, establishing a conductive path between the firstand second prongs 1312, 1322. In the open position, the throw contact1318 is separated from the pole contact 1328 so that there is noconductive path between the first and second prongs 1312, 1322.

FIGS. 13C-D illustrate a SPDT contact set 1301 for a 3-way switch havinga second pole buss 1330 in addition to the SPST contact set 1300 (FIGS.13A-B). The second pole buss 1330 has a third prong 1332 and a secondpole contact 1338. The flexible throw 1314 engages the actuator 1400, asdescribed with respect to FIGS. 14A-B, below, which moves the throwbetween a first position (shown) and a second position. In a firstposition, the throw contact 1318 touches and electrically connects withthe pole contact 1328, establishing a conductive path between the firstand second prongs 1312, 1322. In a second position, the throw contact1318 touches and electrically connects with the second pole contact1338, establishing a conductive path between the first and third prongs1312, 1332.

FIGS. 13E-F illustrate a DPDT contact set 1302 for a 4-way switch havinga second throw buss 1340 and a third pole buss 1350 in addition to theSPDT contact set 1301. The second throw buss 1340 has a second flexiblethrow 1344. The second throw buss 1340 has a fourth prong 1342, a secondflexible throw 1344 and a second throw contact 1348. The second polebuss 1330 has the third pole contact 1339, and the third pole buss 1350has a fourth pole contact 1359. In a first position, the throw contact1318 touches and electrically connects with the pole contact 1328,establishing a conductive path between the first and second prongs 1312,1322. Also, the second throw contact 1348 touches and electricallyconnects with the third pole contact 1339, establishing a conductivepath between the third and fourth prongs 1332, 1342. In a secondposition, the throw contact 1318 touches and electrically connects withthe second pole contact 1338, establishing a conductive path between thefirst and third prongs 1312, 1332. Also, the second throw contact 1348touches and electrically connects with the fourth pole contact 1339,establishing a conductive path between the second and fourth prongs1322, 1342.

FIGS. 14A-B illustrate an actuator 1400 having a front face 1401, a backface 1402 and a lever slot 1410 generally centered within and passingthrough the front and back faces 1401, 1402. The actuator 1400 ispositioned within the switch module 900 (FIG. 10) so that the front face1401 is proximate the front cover 1200 (FIG. 10) and the contact set1300 (FIG. 10) and the back face 1402 is proximate the spring 1000 (FIG.10) and the back cover 1500 (FIG. 10). The lever slot 1410 accommodatesthe switch lever tip 1132 (FIG. 11B), as described above. The front face1401 has a pair of upper arms 1420 and a pair of lower arms 1430extending generally perpendicularly from the front face 1401 so as toengage the contact set 1300 (FIGS. 13A-B). In particular, the flexiblethrow 1314 (FIGS. 13A-B) is engaged between the upper arms 1420. For aDPDT contact set 1302 (FIGS. 13E-F), a second flexible throw 1344 (FIGS.13E-F) is engaged between the lower arms 1430. The back face 1402 has apair of posts 1440 that are slidably retained within back cover guides1550 (FIG. 15A).

FIGS. 15A-B illustrate a rear cover 1500 having an inside face 1502, anoutside face 1501, plug shields 1510, a key bar 1520, side catches 1530,top and bottom latches 1540, actuator guides 1550, a spring hold 1560and contact support structure 1570. As shown in FIG. 15B on the outsideface 1501, the plug shields 1510 advantageously provide the shieldportion of the shielded plugs 930 (FIG. 9B). Specifically, the plugshields 1510 completely surround all sides of the contact set prongs1312, 1322 (FIGS. 13A-B). In this manner, the prongs are not exposedwhen the switch module plugs 930 (FIG. 9B) are engaged with the wiringmodule sockets 1810 (FIG. 18A), even when the switch module 900 (FIGS.9A-B) is partially separated from the wiring module 1600 (FIGS. 16A-B).The key bar 1520 is configured to insert into the wiring module groundsocket 1820 (FIG. 18A), although the key bar 1520 is nonconductive. Thekey bar 1520 assists proper orientation of the switch module 900 (FIGS.9A-B) to the wiring module 1600 (FIGS. 16A-B). The side catches 1530provide apertures that accept and engage the side latches 1230 (FIGS.12A-B), and the top and bottom latches 1540 insert into and engage thetop and bottom catches 1240 (FIGS. 12A-B) so as to releasably securetogether the front cover 1200 (FIGS. 12A-B) and the back cover 1500.

As shown in FIG. 15A on the inside face 1502, the actuator guides 1550slidably retain the actuator posts 1440 (FIG. 14B). The spring hold 1560accommodates and retains the spring 1000 (FIG. 10). The contact supportstructure 1570 consists of slots through the back cover 1500 andstructure extending generally normal to the inside face 1502 thatsupport the contact set 1300 (FIGS. 13A-B). The slots accept the contactset prongs 1312, 1322 (FIGS. 13A-B), which protrude through the backcover 1500 within the plug shields 1510.

Terminal-Block Wiring Module

FIGS. 16A-B illustrate a terminal-block wiring module 1600 having afunctional side 1601 and a wiring side 1602. The functional side 1601has structured sockets 1810 and an off-center ground socket 1820. Thestructured sockets 1810 accept corresponding functional module shieldedplugs, as described with respect to FIG. 20A, below. The wiring module1600 is configured to mount within a conventional electrical box (notshown), secured with attachment screws 1605. A functional module, suchas an outlet module 300 (FIGS. 3A-B) or a switch module 900 (FIGS. 9A-B)plug into the wiring module functional side 1601, secured to the wiringmodule with attachment screws that thread through attachment ears andcorresponding module mounts 1930, as described with respect to FIGS.1-2, above. A power cable (not shown) routed into the electrical boxattaches to a terminal block 1640 (FIG. 16F) accessible from the wiringmodule wiring side 1602, as described with respect to FIGS. 16E-H,below.

As shown in FIGS. 16A-B, a wiring module 1600 advantageously can beinstalled, wired and tested by journeyman electrician at the rough-inphase of building construction. The wiring module 1600 is mounted withinan electrical box according to the type of functional module for whichthe wiring module 1600 will be wired. If the wiring module 1600 ismounted in a first orientation (FIG. 1B), the ground socket 1820 ispositioned below-center. If the wiring module is mounted in a secondorientation (FIGS. 2B, 16A), the ground socket 1820 is positionedabove-center. The ground socket 1820 accepts an outlet module ground bar834 (FIG. 3B) or switch module key bar 1520 (FIG. 9B), which act askeys. Correspondingly, the ground socket 1820 acts as a block thataccepts a functional module key 834 (FIG. 3B), 1520 (FIG. 9B) only whenthe functional module is properly oriented with respect to the wiringmodule 1600 according to module type, such as a switch or outlet. In oneembodiment, the wiring module 1600 is mounted with the ground socket1820 above-center for a switch module 900 (FIGS. 9A-B) and mounted withthe ground socket 1820 below-center for an outlet module 300 (FIGS.3A-B), as described in further detail with respect to FIGS. 16E-H,below.

FIGS. 16C-D illustrate a terminal-block wiring module 1600 havingterminal guards 1700 that advantageously provide covered access to theterminal set 2100 (FIG. 21). In particular, in a closed position (FIGS.16A-B) the terminal guards 1700 protect users from shock and insulatebetween closely mounted high voltage devices. In an open position (FIGS.16C-D), the terminal guards 1700 allow convenient access to the terminalscrews 2140 so as to attach or remove power cable wires from theterminal blocks 1640. As shown in FIG. 16C, a hinge 1702 allows aterminal guard 1700 to move from a closed position (FIGS. 16A-B) to anopen position. A latch 1704 presses into a corresponding catch slot2220, which retains a terminal guard 1700 in a closed position until itis manually opened. As shown in FIG. 16D, in one embodiment a swivelmount 1709 (FIG. 17B) also allows the terminal guard 1700 to swivel fromside to side in an open position, further easing access to the terminalscrews 2140.

FIGS. 16E-F illustrate orientation-dependent labels on the wiring modulefunctional and wiring sides, respectively. As described above, the typeof functional module to be mounted in the wiring module 1600 determinesthe mounted orientation of the wiring module 1600 within an electricalbox. Color coded labels 1620, 1630 on the functional side (FIG. 16E) andwiring labels 1650, 1660 on the wiring side (FIG. 16F) advantageouslyindicate to the journeyman electrician the correct wiring module 1600orientation. The color coded labels 1620, 1630 also advantageouslyindicate the correct functional module to be installed or replaced. Inparticular, as shown in FIG. 16E, the color coded labels include aswitch label 1620 and an outlet label 1630. The switch label 1620 has anorientation indicator 1622 and corresponding text that specify thewiring module orientation for a switch module 900 (FIGS. 2A-B). Inaddition, color boxes 1624 advantageously match color indicators 2310(FIG. 23A) on corresponding switch modules 900. Further, as shown inFIG. 16F, the outlet label 1630 has an orientation indicator 1632 andcorresponding text that specify the wiring module orientation for anoutlet module 300 (FIGS. 1A-B). Also, color boxes 1634 match an outletcolor indicator. In one embodiment, the switch color boxes 1624 areyellow, red and orange matching SP, 3-way and 4-way switch colorindicators, respectively. The outlet color boxes 1634 are dark and lightblue for full hot and half-hot wiring, matching a blue color indicatorfor an outlet module. The color boxes 1624, 1634 are marked by thejourneyman electrician at wiring module installation to visuallyindicate the module type for which the wiring module 1600 was wired.

As shown in FIG. 16F, there are four terminal blocks 1640, each havingterminal labels “1,” “2,” “3” and “4” 1670 identifying the individualterminal blocks T1, T2, T3 and T4 by number. In a switch orientation(shown), switch labels 1650 are advantageously positioned in a mannervisually corresponding to each of the individual terminal blocks 1640.The switch labels 1650 identify switch wiring for each terminal block byswitch type SP, 3-way and 4-way. The outlet labels 1660 are upside downin the switch orientation, visually indicating that they areinapplicable. In an outlet orientation (upside down from that shown),outlet labels 1660 are similarly positioned in a manner visuallycorresponding to each of the individual terminal blocks 1640. The outletlabels 1660 identify outlet wiring. The switch labels 1650 are upsidedown in the outlet orientation, visually indicating that they areinapplicable.

FIGS. 16G-H illustrate switch and outlet wiring schematics,respectively, corresponding to the terminal labels 1670 (FIG. 16F),switch labels 1650 (FIG. 16F) and outlet labels 1660 (FIG. 16F)described with respect to FIG. 16F, above. Graphically depicted aregroups of four terminals 1690 representing the terminal blocks 1640(FIG. 16F). Also depicted are individual terminal blocks 1691,corresponding hot, neutral, traveler and switch wires 1692, and linksand gaps 1693 corresponding to removable breakaways 2116.

FIGS. 17A-B illustrate a terminal-block wiring module 1600 having awiring panel 1800 and a mounting bracket 1900. The wiring panel 1800 hasa front cover 2000, a back cover 2200, a terminal set 2100 and terminalguards 1700. The front cover 2000 and back cover 2200 are securedtogether with a fastener (not shown). The mounting bracket 1900 furthersecures the front cover 2000 to the back cover, as described withrespect to FIGS. 18 20, below. The terminal set 2100 is retained withinthe wiring panel 1800 and provides terminal blocks 1640 (FIG. 16F) forpower cable attachment and provides conductive paths between theterminal blocks 1640 (FIG. 16F) and structured sockets 1810 (FIG. 18A).The mounting bracket 1900 advantageously performs multiple functionsincluding securing the wiring module 1600 to an electrical box (notshown), securing together the front and back covers 2000, 2200,providing a ground bar clip 1902 (FIG. 19A) for contact with a moduleground bar 834 (FIG. 3B) and providing a ground terminal 1907 (FIG. 19A)for a ground wire connection.

As shown in FIGS. 17A-B, the terminal guards 1700 each have a hinge1702, a latch 1704, a mount 1706, 1709 and a grip 1708. The mount 1706,1709 slides into a corresponding guard slot 2210 (FIG. 22A) on each sideof the back cover 2200, which secures each terminal guard 1700 to thewiring panel 1800. The hinge 1702 advantageously allows a terminal guard1700 to move between a closed position (FIGS. 16A-B) blockinginadvertent contact with the terminal blocks 1640 (FIG. 16F) and an openposition (FIGS. 16C-D) allowing access to the terminal blocks 1640 (FIG.16F). The latch 1704 presses into a corresponding catch slot 2220 (FIG.22A) on each side of the back cover 2200, which retains each terminalguard 1700 in a closed position until it is manually opened. A grip 1708assists in latching the terminal guards 1700. A stationary mount 1706(FIG. 17A) holds the terminal guards 1700 in alignment with the terminalscrews 2140 (FIG. 21). Alternatively, a swivel mount 1709 (FIGS. 17B)advantageously allows the terminal guards 1700 to swivel to either side1601, 1602 (FIGS. 16A-B) of the wiring module for easier access to theterminal screws 2140 (FIG. 21).

FIGS. 18A-B illustrate a wiring panel 1800 having a front side 1801 anda back side 1802. The front side 1801 has structured sockets 1810, aground socket 1820 and bracket slots 1830. The back side 1802 hasterminal blocks 1640 (FIG. 16F) formed by a terminal set 2100 (FIG. 21)having terminal screws 2140 (FIG. 21) that are accessed through theterminal guards 1700, as described above.

FIGS. 19A-B illustrate a mounting bracket 1900 having a bracket body1901, a ground clip 1902 and a ground terminal 1907. The ground clip1902 is attached to the bracket body 1901 with a rivet 1905. The groundterminal 1907 provides a ground termination for a ground wire (notshown). The bracket 1900 has swages 1910, box mounts 1920 and modulemounts 1930. The bracket 1900 is configured to be disposed around therear cover 2200 (FIGS. 22A-B) with the swages 1910 inserted throughfront cover slots 2020 (FIGS. 20A-B) and spread against the front coveroutside 2001 so as to secure together the front and rear covers 2000,2200. A fastener 1909 is inserted through the bracket and into thewiring panel front cover 2000, so as to secure together the front andrear covers 2000, 2200. The box mounts 1920 allow the wiring module 1600(FIGS. 16A-B) to be secured to an electrical box (not shown) and areconfigured to removably engage a box cover (FIGS. 27-29). The modulemounts 1930 allow functional modules 300 (FIGS. 3A-B), 900 (FIGS. 9A B)to be secured to the wiring module 1600 (FIGS. 16A-B). The ground clip1902 is configured to physically and electrically connect to a moduleground bar 834 (FIGS. 8A-B).

In an alternative embodiment, the mounting bracket 1900 does not haveswages 1910. Multiple fasteners 1909 are inserted through the mountingbracket 1900 and into the wiring panel front cover 2000, so as to securetogether the front and rear covers 2000, 2200. After the mountingbracket 1900 is attached to the front cover 2000, ears at the top andbottom of the mounting bracket 1900 are bent over and against the frontcover outside 2001 to further secure together the front and rear covers2000, 2200. Trusses are included across or proximate to folded portionsof the mounting bracket 1900 to strengthen the bracket structure. Thebox mount 1920 may have an alternative shape so as to accommodate a boxcover 2700 (FIGS. 27A-B).

FIGS. 20A-B illustrate a front cover 2000 having an outside face 2001and an inside face 2002. As shown in FIG. 20A on the outside face 2001,raised guards 2010 and surrounding channels 2014 provide thenonconductive portions of structured sockets 1810 (FIG. 18A). Eachraised guard 2010 and surrounding channel 2014 are configured to matewith a corresponding plug shield 610 (FIG. 6B). In particular, when afunctional module is plugged into the wiring module 1600 (FIGS. 16A-B),shields 610 (FIG. 6B), 1510 (FIG. 15B) insert into channels 2014, guards2010 insert within shields 610 (FIG. 6B), 1510 (FIG. 15B), and prongs702 (FIGS. 7A-B) plug into power clips 2112 (FIG. 21). This interlockingaction of the shield plugs 330 (FIG. 3B), 930 (FIG. 9B) and thestructured sockets 1810 (FIG. 18A) advantageously provides a fullyenclosed shield as an electrical connection is made between a functionalmodule and a wiring module, in addition to tactile feedback and a solidmechanical and electrical connection. Further, the guards 2010 andchannels 2014 reduce the chance of an inadvertent contact between atool, such as a screwdriver tip, and a hot contact within a socket 1810(FIG. 18A). For example, a tool dragged across the wiring panel frontside 1801 (FIG. 18A) during service will tend to lodge in the channel2014 or against the raised guard 2010 or both. In a particularembodiment, the shields 610 (FIG. 6B), 1510 (FIG. 15B) and thecorresponding channels 2014 and raised guards 2010 are generallyrectangular in shape with rounded corners.

As shown in FIG. 20B, the inside face 2002 has swage slots 2020, aground aperture 2030 and terminal support structure 2050, 2060. Theswage slots 2020 accommodate the mounting bracket swages 1910 (FIG.19A), which assist to secure together the front and back covers 2000,2200. The ground aperture 2030 accommodates a ground bar 834 (FIG. 3B)or key bar 1520 (FIG. 9B) as part of a ground socket 1820 (FIG. 18A).The support structure 2050, 2060 houses the terminal set 2100 (FIGS.21).

FIG. 21 illustrates a terminal set 2100 having contact busses 2110,terminal clamps 2130 and terminal screws 2140. The contact busses 2110each have power clips 2112 that provide the conductor portion of thestructured sockets 1810 (FIG. 18A). The power clips 2112 are configuredto physically and electrically connect with module prongs 702 (FIGS.7A-B), 1312, 1322 (FIGS. 13A-B). The terminal clamps 2130 and terminalscrews 2140 terminate power cables (not shown) to the contact busses2110. The terminal clamps 2130 are configured to secure one wire perchannel 2132. Advantageously, this provides a four-wire capacity foreach of four terminal blocks 1640 (FIG. 16F). In one embodiment, eachterminal block 1640 (FIG. 16F) is configured for four 14 gauge copperwires or two 12 gauge copper wires. Breakaways 2116 are removable toselectively isolate individual terminal blocks 1640 (FIG. 16F).

FIGS. 22A-B illustrate a back cover 2200 having an inside face 2202 andan outside face 2201. The inside face 2202 has mount slots 2210 andcatch slots 2220 that retain the terminal guards 1700 (FIG. 17), asdescribed above. The inside face 2202 also has terminal slots 2230 thatretain the terminal set. The outside face 2201 is shaped to accommodatethe mounting bracket 1900 (FIGS. 19A-B) and accommodate power cableattachment to the terminal blocks 1640 (FIG. 16F).

Dimmer Switch Module

FIGS. 23A-B illustrate a dimmer switch module 2300 having a switch 2410and a dimmer lever 2460 on a front side 2301 and shielded plugs 2330 anda key bar 2350 on a back side 2302. The top of the switch module 2300also has a color label 2310. The color label 2310 corresponds in colorto one of the wiring module color labels 1624. In this manner, theswitch module color label 2310 advantageously provides a visualindication of proper module orientation and avoids installation into awiring module 1600 (FIG. 16E F) wired for a different module type.Similar color labels of differing colors may be applied in a similarfashion to outlet modules 300 (FIGS. 3A-B) and other switch modules 900(FIGS. 9A-B) for the same purpose. FIG. 24 illustrates the dimmer switchmodule 2300 including a switch 2410, a front cover 2420, a bracket 2430,a circuit board 2440, a back cover 2450 and a dimmer lever 2460.

Fixed-Wire Wiring Module

FIGS. 25A-B illustrate a fixed-wire wiring module 2500 having afunctional side 2501 and a wiring side 2502. The wiring module 2500 isconfigured to mount within a conventional electrical box (not shown),secured with attachment screws (not shown) threaded through box mounts2652. A functional module, such as an outlet module 300 (FIGS. 3A-B) ora switch module 900 (FIGS. 9A-B) plug into the wiring module functionalside 2501, secured to the wiring module 2500 with attachment screws (notshown) that thread through attachment ears (not shown) and correspondingmodule mounts 2654, as described with respect to FIGS. 1-2, above. Apower cable (not shown) routed to the electrical box attaches topushwire connectors 2570 at the end of fixed wires 2550 extending fromthe wiring module wiring side 2502.

FIGS. 26A-B illustrate a fixed-wire wiring module 2500 having a frontcover 2610, a back cover 2620, a terminal set 2630, a mounting bracket2650, a ground bar clip 2660 and fasteners 2670. The front cover 2610and back cover 2620 are secured together with the fasteners 2670 andenclose the terminal set 2632. Advantageously, the mounting bracket 2650is partially enclosed by, and retained between, the front cover 2610 andback cover 2620 so as to secure the mounting bracket 2650 to, andmechanically and electrically integrate the mounting bracket with, thewiring module 2500.

As shown in FIGS. 26A-B the front cover 2610 has structured sockets2612, a ground aperture 2614, support structure 2616 and fastener posts2618. The structured sockets 2612 interlock with functional moduleshielded plugs and the ground aperture 2614 accommodates a ground bar orkey bar as part of a ground socket in a manner as described with respectto FIGS. 20A-B, above. The support structure 2616 houses the terminalset 2630. The fastener posts 2618 align with fastener apertures 2624 andaccept the fasteners 2670 securing the front cover 2610 to the backcover 2620.

Also shown in FIGS. 26A-B, the terminal set 2630 has power clips 2632,fixed wire terminals 2634 and breakaways 2638. The power clips 2632provide the conductor portion of the structured sockets 2612 and areconfigured to physically and electrically connect with module prongs ina manner as described with respect to FIG. 21, above. The fixed wireterminals 2634 electrically and mechanically connect a striped end ofthe fixed wires 2550 (FIGS. 25A-B) to the terminal set 2630. Thebreakaways 2638 are removable to selectively isolate individual powerclips 2632.

Further shown in FIGS. 26A-B, the mounting bracket 2650 is adapted to achannel extending lengthwise along the front cover 2610 andcorresponding support structure extending lengthwise along the backcover 2620. The mounting bracket 2650 has box mounts 2652, module mounts2654, a ground clip aperture 2656 and a ground terminal 2658. The boxmounts 2652 accept fasteners (not shown) to secure the bracket to anelectrical box (not shown). The module mounts 2654 accept fasteners (notshown) to secure a functional module (not shown) to the wiring module2500. The ground clip aperture 2656 is adapted to the ground clip 2660,which connects a functional module ground bar electrically andmechanically to the bracket 2650. The bracket has an integrated rivetfor securing the ground clip 2660 within the aperture 2656. The groundterminal 2658 electrically and mechanically connects a striped end of aground one of the fixed wires 2550 (FIGS. 25A-B) to the bracket 2650.

Additionally shown in FIGS. 26A-B, the back cover 2620 has wireapertures 2622, fastener apertures 2624 and a breakaway aperture 2626.The wire apertures 2622 are adapted to the fixed wires 2550 (FIGS.25A-B) so as to provide a seal around and strain relief for the fixedwires and access to the terminal set 2630 and ground terminal 2658. Thefastener apertures 2624 accept that portion of the fasteners 2670 thatthread into or are otherwise secured to the fastener posts 2618. Thebreakaway aperture 2626 allows user access to the breakaways 2638 withinan assembled wiring module 2500.

Electrical Box Cover

FIGS. 27A-B illustrate an electrical box cover 2700 having a generallyplanar cover plate 2710, clamps 2720, catches 2730, trusses 2740 andmarkers 2750. The cover plate 2710 has a front side 2701 and a back side2702. The clamps 2720 are located, one each, generally centered on thetop and bottom of the cover plate 2710 and extend generallyperpendicularly from the back side 2702. The catches 2730 are apertures,one for each catch 2730, that are generally centered on the catches 2720and extending along the juncture between the catches 2730 and the coverplate 2710. The trusses 2740 are protrusions on the cover plate 2740that extend substantially along the length of the front side 2701,providing structural support to resist bending of the cover plate 2710.The markers 2750 are generally round protrusions on the front side 2701of the cover plate 2740 located, one each, proximate the top and bottomof the cover plate 2740.

FIGS. 28A-B illustrate an electrical box 2800 that is covered anduncovered, respectively, by a box cover 2700, as described with respectto FIGS. 27A-B, above. The box cover 2700 removably mounts over theelectrical box open face 2801 so as to prevent material such as plasterand paint from fouling the wiring module 1600 during the makeup phase ofconstruction. Advantageously, the box cover 2700 mounts generally flushwith the electrical box open face 2801 and, hence, generally flush withinstalled drywall so as not to interfere with drywall constructionduring the makeup phase. Drywall, once loosely positioned, can bepressed against the box cover 2700. In doing so, the markers 2750 dimplethe drywall, advantageously marking the location of the electrical box2800 so that drywall cutouts can be accurately made to accommodate theelectrical box 2800.

As shown in FIGS. 28A-B, the box cover 2700 is installed on the boxmounts 1920 of a wiring module 1600 mounted within the electrical box2800. In particular, the clamps 2720 flex somewhat to slide over the boxmounts 1920 until the box mounts 1920 insert into corresponding catches2730. The box cover 2700 can be easily removed by flexing the clamps2720 so that a box mount 1920 clears a corresponding catch 2730.

FIG. 29 illustrate a 2-gang electrical box 2900 with overlapping boxcovers 2700. The box covers 2700 are configured so that a first portion2791 of one cover overlaps a second portion 2792 of another cover so asto prevent drywall related material from entering between the covers2700 and fouling the electrical box 2900 interior.

Terminal Shield

FIGS. 30A-B illustrate a terminal-block wiring module 1600 having aterminal shield 3100 installed on a wiring side 1602 using fasteners1909. The terminal shield 3100 advantageously prevents bare copperground wires (not shown), which typically are connected between theground terminal 1907 (FIG. 17A) and an electrical box (not shown), frominadvertently protruding through the back cover 2200 (FIG. 17A) andshort circuiting the terminal set 2100 (FIG. 17A).

FIGS. 31A-B illustrate a terminal shield 3100 having a front side 3101,a back side 3102 and a spine 3105. Mounting ears 3110 extend from bothends of the spine 3105, and shield wings 3120 extend from both sides ofthe spine 3105. Breakaway guards 3130 extend from a central portion ofeach shield wing 3120. A V-shaped hinge 3135 extending across a portionof each breakaway guard 3130 allows the breakaway guards 3130 to flexsomewhat to gain access for removal of one or both of the breakaways2116 (FIG. 16F), as described with respect to FIGS. 16G-H, above.Mounting apertures 3140 are defined in the mounting ears 3110, wireapertures 3150 are defined in the shield wings 3120, and a bracketaperture 3160 is defined in a central portion of the spine 3105.

As shown in FIGS. 31A-B, the terminal shield 3100 is installed with theback side 3102 proximate the wiring module 1600 (FIG. 30A) and the frontside 3101 distal the wiring module 1600 (FIG. 30A). In particular, thespine 3105 fits against the bracket 1900 and the bracket aperture 3160accommodates protrusions due to the ground clip 1902 (FIG. 17A) or itsassociated fastener. The mounting apertures 3140 accept the fasteners1909 (FIG. 30A), which also secure together the wiring module 1600 (FIG.30A). The shield wings 3120 cover exposed portions of the terminal set2100 (FIG. 17A), and the wire apertures 3150 accommodate wire ends thatare connected to the terminal set 2100 (FIG. 17A).

Other Functional Modules

Although described above with respect to outlet and switch modules, theelectrical distribution system may operate in conjunction with a varietyof functional modules providing various electrical functions, such assecurity modules, data transfer modules, computing modules, homeentertainment modules and intelligent home product modules to name afew. For example, a security module may incorporate a video camera ormotion sensor. A data transfer module may incorporate data storagedevices, wireless transceivers or AC power line transceivers. Acomputing module may incorporate a microprocessor, a data entry ordisplay device, for example. A home entertainment module may work inconjunction with speakers, LCD panels or plasma TVs. A home productmodule, for instance, may incorporate a microcontroller and a wirelessor an AC power line transceiver for appliance control.

A safety module electrical distribution system has been disclosed indetail in connection with various embodiments. These embodiments aredisclosed by way of examples only and are not to limit the scope of theclaims that follow. One of ordinary skill in the art will appreciatemany variations and modifications.

1. A method of manufacturing a wiring module adapted to fit within anelectrical box, the wiring module adapted to connect to a functionalmodule, the method comprising: terminating at least four electricalwires to corresponding terminals in a terminal set; placing saidterminals within a non-conductive wiring piece or a non-conductivefunctional piece; and connecting said non-conductive functional piece tosaid non-conductive wiring piece, leaving a plurality of the terminalsexposed via a plurality of openings in said functional piece, and withsaid at least four wires extending from said wiring module, wherein saidwiring module comprises said non-conductive functional piece and saidnon-conductive wiring piece and is configured to fit within saidelectrical box.
 2. The method of claim 1, further comprising the step ofattaching at least one functional module to the wiring module.
 3. Themethod of claim 2, wherein the functional module comprises a three wayswitch.
 4. The method of claim 2, wherein the functional modulecomprises a four way switch.
 5. The method of claim 2, wherein thefunctional module comprises a dimmer.
 6. The method of claim 1, furthercomprising the step of affixing a protective cover over the wiringmodule, said cover preventing installation of a functional module. 7.The method of claim 1, further comprising the step of affixing anelectrical box to at least one of the fixed wires.
 8. The method ofclaim 1, further comprising the step of affixing a label to the wiringmodule, said label being for marking wiring or location information. 9.The method of claim 1, wherein one or more of said fixed wires has anend adapted to attach a wire connector.
 10. A wiring module adapted tofit within an electrical box, the wiring module adapted to connect towith a functional module, the wiring module comprising: at least fourterminals in a terminal set configured to terminate at least four wires;a non-conductive wiring piece and a non-conductive functional piece thatare configured to enclose at least a portion of the terminal set; andconnecting said non-conductive functional piece to said non-conductivewiring piece, leaving a plurality of the terminals exposed via aplurality of openings in said functional piece, and with the at leastfour wires extending from said wiring module, wherein said wiring modulecomprises said non-conductive functional piece and said non-conductivewiring piece and is configured to fit within said electrical box. 11.The wiring module of claim 10, further comprising at least onefunctional module connected thereto.
 12. The wiring module of claim 11,wherein the functional module comprises a three way switch.
 13. Thewiring module of claim 11, wherein the functional module comprises afour way switch.
 14. The wiring module of claim 11, wherein thefunctional module comprises a dimmer.
 15. The wiring module of claim 10,further comprising a protective cover over the wiring module, said coverpreventing installation of a functional module.
 16. The wiring module ofclaim 10, further comprising an electrical box affixed to at least oneof the fixed wires.
 17. The wiring module of claim 10, furthercomprising a label, said label being for marking wiring or locationinformation.
 18. The wiring module of claim 10, wherein one or more ofsaid at least four wires has an end adapted to attach a wire connector.